CA2702278C - Laser cladding device with an improved nozzle - Google Patents
Laser cladding device with an improved nozzle Download PDFInfo
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- CA2702278C CA2702278C CA2702278A CA2702278A CA2702278C CA 2702278 C CA2702278 C CA 2702278C CA 2702278 A CA2702278 A CA 2702278A CA 2702278 A CA2702278 A CA 2702278A CA 2702278 C CA2702278 C CA 2702278C
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- 238000004372 laser cladding Methods 0.000 title claims abstract description 70
- 239000011248 coating agent Substances 0.000 claims abstract description 75
- 238000000576 coating method Methods 0.000 claims abstract description 75
- 238000007493 shaping process Methods 0.000 claims description 25
- 239000007789 gas Substances 0.000 description 41
- 239000011261 inert gas Substances 0.000 description 38
- 239000012255 powdered metal Substances 0.000 description 36
- 239000000463 material Substances 0.000 description 11
- 239000002184 metal Substances 0.000 description 10
- 229910052751 metal Inorganic materials 0.000 description 10
- 238000005253 cladding Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 238000009825 accumulation Methods 0.000 description 4
- 230000003466 anti-cipated effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
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- 239000000843 powder Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000012800 visualization Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
- C23C26/02—Coating not provided for in groups C23C2/00 - C23C24/00 applying molten material to the substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
- B05B1/24—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means incorporating means for heating the liquid or other fluent material, e.g. electrically
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
- B05B7/228—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using electromagnetic radiation, e.g. laser
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/12—Applying particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/16—Flocking otherwise than by spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
- C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
Abstract
A laser cladding device for applying a coating to a part comprising a laser which can generate laser light, which is adapted to heat the coating and the part, a main body defining a laser light channel adapted to transmit the laser light to the part, a coating channel adapted to transmit the coating to the part, and a vacuum channel and a nozzle having an exit. The nozzle comprises a delivery port at one end of the laser light channel, a coating port at one end of the coating channel, and a vacuum port at one end of the vacuum channel, wherein the vacuum port is positioned generally adjacent the delivery port. In operation the vacuum port draws a vacuum, pulling the coating towards the part.
Description
LASER CLADDING DEVICE WITH AN IMPROVED NOZZLE
FIELD OF THE INVENTION
The present invention relates to the field of laser cladding, and more particularly to the laser cladding devices having an improved nozzle.
BACKGROUND OF THE INVENTION
Laser cladding by powder metal injection is used in manufacturing, component repair, rapid prototyping and coating. A laser beam travels down a passage to exit out a port in focused alignment with a flow of powdered metal, typically a conical flow around the laser. The laser melts both a thin layer of a surface of a part and the metal powder introduced to the surface, allowing the molten powdered metal to fuse with the surface of the part. This technique is well know for producing parts with enhanced metallurgical qualities such as a superior coating with reduced distortion and enhanced surface quality. Layers of various thicknesses can be formed on the part using laser cladding with the general range being 0.1 to 2 mm in a single pass.
FIELD OF THE INVENTION
The present invention relates to the field of laser cladding, and more particularly to the laser cladding devices having an improved nozzle.
BACKGROUND OF THE INVENTION
Laser cladding by powder metal injection is used in manufacturing, component repair, rapid prototyping and coating. A laser beam travels down a passage to exit out a port in focused alignment with a flow of powdered metal, typically a conical flow around the laser. The laser melts both a thin layer of a surface of a part and the metal powder introduced to the surface, allowing the molten powdered metal to fuse with the surface of the part. This technique is well know for producing parts with enhanced metallurgical qualities such as a superior coating with reduced distortion and enhanced surface quality. Layers of various thicknesses can be formed on the part using laser cladding with the general range being 0.1 to 2 mm in a single pass.
2 2 [0004] Known nozzles for laser cladding have various levels of complexity. A common
3 type is based on a concentric design with the laser beam passing through the center of
4 the nozzle. Surrounding the central laser beam are concentric ports that may be formed as an annulus or continuous ring, segments of rings, or holes which deliver an inert 6 shield inert gas, the powdered metal carried by an inert gas, and in some cases an 7 outer shaping gas. However, such known nozzles for laser cladding assemblies are 8 limited in that the majority of the gas flow is deflected away from the laser weld zone.
9 Therefore a significant amount of the powdered metal directed at the weld zone actually escapes the process altogether. It would be desirable to provide a laser cladding 11 device where the amount of powdered metal delivered to the laser welding zone and 12 therefore to the part is increased.
16 [0005] In accordance with a first aspect, a laser cladding device for applying a coating to 17 a part comprising a laser which can generate laser light, which is adapted to heat the 18 coating and the part, a main body defining a laser light channel adapted to transmit the 19 laser light to the part, a coating channel adapted to transmit the coating to the part, and a vacuum channel and a nozzle having an exit. The nozzle comprises a delivery port at 21 one end of the laser light channel, a coating port at one end of the coating channel, and 22 a vacuum port at one end of the vacuum channel, wherein the vacuum port is 1 positioned generally adjacent the delivery port. In operation the vacuum port draws a 2 vacuum, pulling the coating towards the part.
4 [0006] From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the 6 present invention provides a significant advance in the technology of laser cladding 7 devices. Particularly significant in this regard is the potential the invention affords for 8 providing a high quality, low cost laser cladding device with greatly increased powder 9 catchment. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below.
14 [0007] Fig. 1 shows a laser cladding device in accordance with a preferred embodiment, showing a manipulator, a main body and a nozzle.
17 [0008] Fig. 2 is a cross section view of the nozzle of Fig. 1.
19 [0009] Fig. 3 is a cross section view of the nozzle of Fig. 1 shown with the flow of gases and powdered metal coating shown pulled toward the vacuum port.
22 [0010] Fig. 4 is a schematic block diagram of a preferred embodiment of a control 23 system for the laser cladding device.
2 [0011] Fig. 5 is an alternate preferred embodiment of a nozzle of a laser cladding 3 device, showing a vacuum port provided with side ports.
[0012] Fig. 6 is a cross section view of the nozzle of Fig. 5 shown with the flow of inert 6 gas and powdered metal shown pulled toward the vacuum port.
8 [0013] Fig. 7 is another alternate preferred embodiment of a laser cladding device, 9 shown with an adjustably mounted lens.
11 [0014] Fig. 8 is a schematic diagram of a preferred embodiment of a controller for the 12 laser cladding device of Fig. 7.
14 [0015] Fig. 9 is an end view of the laser cladding device, taken along line 9-9 in Fig. 1, showing the ports.
17 [0016] It should be understood that the appended drawings are not necessarily to scale, 18 presenting a somewhat simplified representation of various preferred features 19 illustrative of the basic principles of the invention. The specific design features of the laser cladding device, as disclosed here, including, for example, the specific dimensions 21 of the vacuum port, will be determined in part by the particular intended application and 22 use environment. Certain features of the illustrated embodiments have been enlarged 23 or distorted relative to others to improve visualization and clear understanding. In 1 particular, thin features may be thickened, for example, for clarity of illustration. All 2 references to direction and position, unless otherwise indicated, refer to the orientation 3 illustrated in the drawings.
9 Therefore a significant amount of the powdered metal directed at the weld zone actually escapes the process altogether. It would be desirable to provide a laser cladding 11 device where the amount of powdered metal delivered to the laser welding zone and 12 therefore to the part is increased.
16 [0005] In accordance with a first aspect, a laser cladding device for applying a coating to 17 a part comprising a laser which can generate laser light, which is adapted to heat the 18 coating and the part, a main body defining a laser light channel adapted to transmit the 19 laser light to the part, a coating channel adapted to transmit the coating to the part, and a vacuum channel and a nozzle having an exit. The nozzle comprises a delivery port at 21 one end of the laser light channel, a coating port at one end of the coating channel, and 22 a vacuum port at one end of the vacuum channel, wherein the vacuum port is 1 positioned generally adjacent the delivery port. In operation the vacuum port draws a 2 vacuum, pulling the coating towards the part.
4 [0006] From the foregoing disclosure and the following more detailed description of various preferred embodiments it will be apparent to those skilled in the art that the 6 present invention provides a significant advance in the technology of laser cladding 7 devices. Particularly significant in this regard is the potential the invention affords for 8 providing a high quality, low cost laser cladding device with greatly increased powder 9 catchment. Additional features and advantages of various preferred embodiments will be better understood in view of the detailed description provided below.
14 [0007] Fig. 1 shows a laser cladding device in accordance with a preferred embodiment, showing a manipulator, a main body and a nozzle.
17 [0008] Fig. 2 is a cross section view of the nozzle of Fig. 1.
19 [0009] Fig. 3 is a cross section view of the nozzle of Fig. 1 shown with the flow of gases and powdered metal coating shown pulled toward the vacuum port.
22 [0010] Fig. 4 is a schematic block diagram of a preferred embodiment of a control 23 system for the laser cladding device.
2 [0011] Fig. 5 is an alternate preferred embodiment of a nozzle of a laser cladding 3 device, showing a vacuum port provided with side ports.
[0012] Fig. 6 is a cross section view of the nozzle of Fig. 5 shown with the flow of inert 6 gas and powdered metal shown pulled toward the vacuum port.
8 [0013] Fig. 7 is another alternate preferred embodiment of a laser cladding device, 9 shown with an adjustably mounted lens.
11 [0014] Fig. 8 is a schematic diagram of a preferred embodiment of a controller for the 12 laser cladding device of Fig. 7.
14 [0015] Fig. 9 is an end view of the laser cladding device, taken along line 9-9 in Fig. 1, showing the ports.
17 [0016] It should be understood that the appended drawings are not necessarily to scale, 18 presenting a somewhat simplified representation of various preferred features 19 illustrative of the basic principles of the invention. The specific design features of the laser cladding device, as disclosed here, including, for example, the specific dimensions 21 of the vacuum port, will be determined in part by the particular intended application and 22 use environment. Certain features of the illustrated embodiments have been enlarged 23 or distorted relative to others to improve visualization and clear understanding. In 1 particular, thin features may be thickened, for example, for clarity of illustration. All 2 references to direction and position, unless otherwise indicated, refer to the orientation 3 illustrated in the drawings.
5 DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
6
7 [0017] It will be apparent to those skilled in the art, that is, to those who have knowledge
8 or experience in this area of technology, that many uses and design variations are
9 possible for the laser cladding device disclosed here. The following detailed discussion of various alternative and preferred features and embodiments will illustrate the general 11 principles of the invention with reference to a laser cladding device suitable for use in 12 the manufacture of metal parts with enhanced metallurgical properties.
Other 13 embodiments suitable for other applications will be apparent to those skilled in the art 14 given the benefit of this disclosure.
16 [0018] Turning now to the drawings, Fig. 1 shows a portion of a laser cladding device 10 17 in accordance with a preferred embodiment. The device is adjustably mounted via 18 manipulator arm 22 connected to main body 30. A nozzle 20 is attached to the main 19 body. The nozzle 20 and main body 30 are preferably formed as separate components, but could be formed of a one piece or unitary construction. Laser light, such as laser 21 beam light from a fiber laser, along with a coating such as a powdered metal are 22 introduced to a part at a work zone adjacent the nozzle. Fig. 2 shows a cross section 23 view of a preferred embodiment of the nozzle 20. The body 30 of the laser cladding 1 nozzle provides mounting for the nozzle and all of the other nozzle components. The 2 laser beam, not shown, passes along a central axis of the laser cladding nozzle through 3 a laser light channel 118, entering a delivery port 15 formed in the laser cladding nozzle.
4 As seen in Fig. 2, laser light travels from above and can be focused by lens 26 at a point below and outside an end or exit 99 of the laser cladding nozzle, i.e., at a part in a 6 work zone.
8 [0019] After the laser beam passes through the lens 26 the light can pass through an 9 optional window 28 in the channel 118. The window may be mounted and located by a spacer ring 112 on the main body as shown in Fig. 2. The laser beam then passes into 11 the delivery port 15, formed in the nozzle. The delivery port 15 may have, for example, a 12 generally circular cross section. Further, an inert gas, not shown may pressurize the 13 delivery port 15. This shield gas aids in preventing the accumulation of smoke, 14 powdered metal, and work zone splatter on the window 28, or when the window is not present, on the lens 26. The spacer ring 112 may be adjustable. The lens 26 and 16 window 28 may be optionally adjustable as well.
18 [0020] At the end or exit 99 of the nozzle a series of materials are introduced. From the 19 center delivery port 15, the laser light and a shield gas exits at the end 99. In accordance with a highly advantageous feature, a vacuum port 14 is provided generally 21 adjacent the delivery port 15. In operation a vacuum or reduced pressure is drawn at 22 the vacuum port 14. In effect, other materials are pulled toward the vacuum port 14.
23 The use of a negative pressure or vacuum zone near the central area of the laser cladding nozzle, i.e., near the delivery port, serves to remove some of the inert gas being used to deliver the powdered metal coating and some of the gas which provides the shaping gas flow. The net effect of this negative pressure or vacuum zone is to pull the gas flows towards the central axis of the laser cladding nozzle so that more material arrives at the work zone. This advantageously results in the deposition of more powdered metal in the work zone and less of the powdered metal escaping the work zone.
Fig. 2 shows the vacuum port 14 connected to a vacuum channel 109. There may be one of more vacuum channels 109, depending in part upon the anticipated flow of gas and material. Also shown is coating port 12 connected to a coating channel 110, and an optional shaping gas port 16 connected to a shaping gas channel 111. As shown in Fig. 2, each port has a generally conical shape. The ports are preferably manufactured from materials that can accommodate high temperatures, such as ceramics, tungsten, titanium, chromalloyTM, etc. There is no need for them all to be manufactured from the same materials; however, it is expected that the innermost conical shapes are going to be exposed to the highest temperatures as a result of the flow of material and gases. It will be readily apparent to those skilled in the art, given the benefit of this disclosure, that the relative lengths of the ports are for illustrative purposes only and may be adjusted depending upon a given application. As another example, a length of the shaping gas port can exceed a length of the coating port. Also, a length of the coating port can exceed a length of the vacuum port, and a length of the vacuum port can exceed a length of the delivery port for the laser light. Each port can 1 advantageously form at least part of a ring or annulus around an adjacent port. In the 2 preferred embodiment shown in Fig. 2, the delivery port 15 is in the center, and the 3 vacuum port 14 is immediately adjacent the delivery port, that is, they share a common 4 wall over at least a portion of their length near the end 99. Most preferably the vacuum port circumferentially surrounds the delivery port 15. The coating port 12 is positioned 6 adjacent the vacuum port 14, and the optional gas shaping port 16 is the outermost 7 annulus. Fig. 9 is an end view showing concentric ports 16, 12, 14 positioned around a 8 delivery port 15 for the laser light.
[0022] The laser cladding device comprises several components arranged in such a 11 way as to provide flow paths to draw a vacuum, a flow path for an inert gas plus 12 powdered metal or other suitable coating, and for a flow path for an optional shaping 13 gas flow. Most preferably the geometry of the laser cladding nozzle's construction is 14 such that the convergence point of all of the gas flows is approximately coincident with a laser focal point. The coating port 12 delivers a coating material to the part to be 16 subjected to the laser cladding process. Typically the coating port delivers a coating 17 material in the form of a powdered metal in combination with an inert gas which urges 18 the powdered metal towards the part. The inert gases used in the laser cladding 19 process can be helium, argon, etc. each of which provides various advantages based on their physical properties, such as, specific heat, density, etc.
22 [0023] An optional chamber 106 in the vacuum port 14 may provide an accumulation 23 volume between the vacuum port and the vacuum channel 109. There may be one of 1 more vacuum channel to vacuum port connections depending upon the anticipated flow 2 of inert gas and powdered metal. Optional chamber 107 in the coating port can provide 3 an accumulation volume between the inert gas and powdered metal connection channel 4 110 and coating port 12. There may be one of more inert gas and powdered metal piping connections depending upon the anticipated flow of inert gas and powdered 6 metal. Optional chamber 108 in the shaping gas port 16 aligns with the shaping gas 7 channel 111 providing an accumulation volume between the shaping gas channel 111 8 and the shaping gas port 16. There may be one of more shaping gas piping connections 9 depending upon the anticipated flow of shaping gas.
11 [0024] Fig. 3 shows an approximate flow of gases and coating materials in response to 12 the vacuum pulled by the vacuum port 14. Arrow 404 corresponds to the direction of 13 laser light, heading parallel to central axis 402 to part 401 in the work zone. The inert 14 gas flows out of and into the laser cladding nozzle are shown with moderate levels of vacuum applied. Only the gas flows to one side of the laser cladding nozzle centerline, 16 402, are shown for clarity. The influence of the surface of the part 401 that is being laser 17 clad is to ultimately force all of the exiting inert gas flows, 404, 406, and 407 outward in 18 a radial direction away from the nozzle centerline, 402 after they impinge onto the 19 surface of part 401. The influence of a moderate vacuum induces a flow 403 of inert gases and solids (from the coating port 12) into the laser cladding nozzle vacuum port 21 14. In the cases where there is an inert gas flow into the interior zone of the laser 22 cladding nozzle vacuum port then some of that inert gas 404 will flow out of the interior 23 zone and towards the surface of the part 401 being clad while another portion of that 1 gas 405 will flow into the vacuum port 14 to form part of the vacuum channel flow 403.
2 The majority of the inert gas and powdered metal flow 406 exiting from the coating port 3 12 travels towards the surface of part 401. However some of the flow 408 is pulled 4 towards the nozzle centerline 402 and enters the vacuum port 14 to make up part of the 5 flow 403. The net effect of the diversion of flow of the inert gas and powdered metal 406 6 by the flow 408 created by the vacuum channel flow 403 is to keep more of the powered 7 metal near the centerline 402 of the laser cladding nozzle, and thereby improve metal 8 cladding efficiency. The inert shaping gas flow 407 out of the shaping gas port 16 is also 9 influenced by the flow of gases 403 into the vacuum port 14. While some of the shaping
Other 13 embodiments suitable for other applications will be apparent to those skilled in the art 14 given the benefit of this disclosure.
16 [0018] Turning now to the drawings, Fig. 1 shows a portion of a laser cladding device 10 17 in accordance with a preferred embodiment. The device is adjustably mounted via 18 manipulator arm 22 connected to main body 30. A nozzle 20 is attached to the main 19 body. The nozzle 20 and main body 30 are preferably formed as separate components, but could be formed of a one piece or unitary construction. Laser light, such as laser 21 beam light from a fiber laser, along with a coating such as a powdered metal are 22 introduced to a part at a work zone adjacent the nozzle. Fig. 2 shows a cross section 23 view of a preferred embodiment of the nozzle 20. The body 30 of the laser cladding 1 nozzle provides mounting for the nozzle and all of the other nozzle components. The 2 laser beam, not shown, passes along a central axis of the laser cladding nozzle through 3 a laser light channel 118, entering a delivery port 15 formed in the laser cladding nozzle.
4 As seen in Fig. 2, laser light travels from above and can be focused by lens 26 at a point below and outside an end or exit 99 of the laser cladding nozzle, i.e., at a part in a 6 work zone.
8 [0019] After the laser beam passes through the lens 26 the light can pass through an 9 optional window 28 in the channel 118. The window may be mounted and located by a spacer ring 112 on the main body as shown in Fig. 2. The laser beam then passes into 11 the delivery port 15, formed in the nozzle. The delivery port 15 may have, for example, a 12 generally circular cross section. Further, an inert gas, not shown may pressurize the 13 delivery port 15. This shield gas aids in preventing the accumulation of smoke, 14 powdered metal, and work zone splatter on the window 28, or when the window is not present, on the lens 26. The spacer ring 112 may be adjustable. The lens 26 and 16 window 28 may be optionally adjustable as well.
18 [0020] At the end or exit 99 of the nozzle a series of materials are introduced. From the 19 center delivery port 15, the laser light and a shield gas exits at the end 99. In accordance with a highly advantageous feature, a vacuum port 14 is provided generally 21 adjacent the delivery port 15. In operation a vacuum or reduced pressure is drawn at 22 the vacuum port 14. In effect, other materials are pulled toward the vacuum port 14.
23 The use of a negative pressure or vacuum zone near the central area of the laser cladding nozzle, i.e., near the delivery port, serves to remove some of the inert gas being used to deliver the powdered metal coating and some of the gas which provides the shaping gas flow. The net effect of this negative pressure or vacuum zone is to pull the gas flows towards the central axis of the laser cladding nozzle so that more material arrives at the work zone. This advantageously results in the deposition of more powdered metal in the work zone and less of the powdered metal escaping the work zone.
Fig. 2 shows the vacuum port 14 connected to a vacuum channel 109. There may be one of more vacuum channels 109, depending in part upon the anticipated flow of gas and material. Also shown is coating port 12 connected to a coating channel 110, and an optional shaping gas port 16 connected to a shaping gas channel 111. As shown in Fig. 2, each port has a generally conical shape. The ports are preferably manufactured from materials that can accommodate high temperatures, such as ceramics, tungsten, titanium, chromalloyTM, etc. There is no need for them all to be manufactured from the same materials; however, it is expected that the innermost conical shapes are going to be exposed to the highest temperatures as a result of the flow of material and gases. It will be readily apparent to those skilled in the art, given the benefit of this disclosure, that the relative lengths of the ports are for illustrative purposes only and may be adjusted depending upon a given application. As another example, a length of the shaping gas port can exceed a length of the coating port. Also, a length of the coating port can exceed a length of the vacuum port, and a length of the vacuum port can exceed a length of the delivery port for the laser light. Each port can 1 advantageously form at least part of a ring or annulus around an adjacent port. In the 2 preferred embodiment shown in Fig. 2, the delivery port 15 is in the center, and the 3 vacuum port 14 is immediately adjacent the delivery port, that is, they share a common 4 wall over at least a portion of their length near the end 99. Most preferably the vacuum port circumferentially surrounds the delivery port 15. The coating port 12 is positioned 6 adjacent the vacuum port 14, and the optional gas shaping port 16 is the outermost 7 annulus. Fig. 9 is an end view showing concentric ports 16, 12, 14 positioned around a 8 delivery port 15 for the laser light.
[0022] The laser cladding device comprises several components arranged in such a 11 way as to provide flow paths to draw a vacuum, a flow path for an inert gas plus 12 powdered metal or other suitable coating, and for a flow path for an optional shaping 13 gas flow. Most preferably the geometry of the laser cladding nozzle's construction is 14 such that the convergence point of all of the gas flows is approximately coincident with a laser focal point. The coating port 12 delivers a coating material to the part to be 16 subjected to the laser cladding process. Typically the coating port delivers a coating 17 material in the form of a powdered metal in combination with an inert gas which urges 18 the powdered metal towards the part. The inert gases used in the laser cladding 19 process can be helium, argon, etc. each of which provides various advantages based on their physical properties, such as, specific heat, density, etc.
22 [0023] An optional chamber 106 in the vacuum port 14 may provide an accumulation 23 volume between the vacuum port and the vacuum channel 109. There may be one of 1 more vacuum channel to vacuum port connections depending upon the anticipated flow 2 of inert gas and powdered metal. Optional chamber 107 in the coating port can provide 3 an accumulation volume between the inert gas and powdered metal connection channel 4 110 and coating port 12. There may be one of more inert gas and powdered metal piping connections depending upon the anticipated flow of inert gas and powdered 6 metal. Optional chamber 108 in the shaping gas port 16 aligns with the shaping gas 7 channel 111 providing an accumulation volume between the shaping gas channel 111 8 and the shaping gas port 16. There may be one of more shaping gas piping connections 9 depending upon the anticipated flow of shaping gas.
11 [0024] Fig. 3 shows an approximate flow of gases and coating materials in response to 12 the vacuum pulled by the vacuum port 14. Arrow 404 corresponds to the direction of 13 laser light, heading parallel to central axis 402 to part 401 in the work zone. The inert 14 gas flows out of and into the laser cladding nozzle are shown with moderate levels of vacuum applied. Only the gas flows to one side of the laser cladding nozzle centerline, 16 402, are shown for clarity. The influence of the surface of the part 401 that is being laser 17 clad is to ultimately force all of the exiting inert gas flows, 404, 406, and 407 outward in 18 a radial direction away from the nozzle centerline, 402 after they impinge onto the 19 surface of part 401. The influence of a moderate vacuum induces a flow 403 of inert gases and solids (from the coating port 12) into the laser cladding nozzle vacuum port 21 14. In the cases where there is an inert gas flow into the interior zone of the laser 22 cladding nozzle vacuum port then some of that inert gas 404 will flow out of the interior 23 zone and towards the surface of the part 401 being clad while another portion of that 1 gas 405 will flow into the vacuum port 14 to form part of the vacuum channel flow 403.
2 The majority of the inert gas and powdered metal flow 406 exiting from the coating port 3 12 travels towards the surface of part 401. However some of the flow 408 is pulled 4 towards the nozzle centerline 402 and enters the vacuum port 14 to make up part of the 5 flow 403. The net effect of the diversion of flow of the inert gas and powdered metal 406 6 by the flow 408 created by the vacuum channel flow 403 is to keep more of the powered 7 metal near the centerline 402 of the laser cladding nozzle, and thereby improve metal 8 cladding efficiency. The inert shaping gas flow 407 out of the shaping gas port 16 is also 9 influenced by the flow of gases 403 into the vacuum port 14. While some of the shaping
10 gas flow 409 is still diverted away from the nozzle centerline, 402 as shown by gas
11 flows 409 some, 410 provides additional radial pressure on the inert gas and powdered
12 metal flow 406, thereby providing additional impetus for the powdered metal to stay in
13 the proximity of the nozzle centerline, 402.
14 [0025] As noted above, some of inert gas flow being delivered by the nozzle will be 16 drawn into the reduced pressure or vacuum zone or opening near the center of the laser 17 cladding nozzle. The amount of inert gas drawn in will depend on three factors, the size 18 of the opening, the shape and location of the opening, and the magnitude of the 19 negative pressure being applied. Based on the values of the above three factors, it is possible to foresee the case where the majority of the inert gas being delivered by the 21 nozzle can be drawn into the negative pressure or vacuum opening in the nozzle. In fact 22 if all of the values are arranged properly it would also be possible to recapture the 23 majority of the powdered metal being delivered by the nozzle. This ability to either recapture or control the amount of powdered metal would allow for a quick and easily controllable means to reduce or cut off the flow of powdered metal as required during the laser cladding process. Such a reduction or complete cut off of powdered metal flow could be advantageous during a laser cladding process that is under automatic computer control, allowing reduction in metal deposition during directional changes or reversal of the path that the laser cladding nozzle is traversing.
Fig. 4 the shows a schematic block diagram of the overall device controller and related components required for using the laser cladding device 10. Overall system control is provided by the master control computer 327 which provides coordination information to and receives data from the control elements in the system; namely, the robot controller, 328, the laser controller, 329, the shaping gas flow control valve, 303, the powdered metal mixing system, 308, the inert gas control valve for the powdered mixing unit, 313, the vacuum flow control valve, 316, the weld zone vision control system, 330, and the optional interior of the nozzle inert gas control valve, 325. There may of course be many other secondary control sensors that supply information on various aspects of the laser cladding system's operation to the master control computer, 327, their omission from Fig. 4 is done for the sake of simplicity only.
During operation, the laser cladding nozzle 20 is moved over the surface of the part being clad 401 through the use of a robot manipulator 305 under the control of the robot controller 328 as directed by the master control computer 327. Simultaneous with the movement of the laser cladding nozzle 20 over the surface of the part 401 being 1 clad, the laser, not shown, is focused by the laser cladding nozzle optics onto the 2 surface of part 401. At the same time the laser controller 329 controls the power output 3 of the laser as directed by the master control computer 327. Also at the same time, all 4 under the control of the master control computer 327: 1) the flow 302 of the inert shaping gas from supply tank #1 is controlled by flow control valve 303; 2) the flow 311 6 of inert gas from supply tank # 2 is metered into the powdered metal mixing system 308 7 by the gas flow control valve 313, while powdered metal is drawn from the powdered 8 metal supply tank 310 before the combined inert gas and powdered metal is delivered 9 to the laser cladding nozzle port 14; 3) the vacuum control valve 316 is used to control the level of vacuum present at the laser cladding nozzle port 14, the inert gases and 11 solids collected by the nozzle are passed through the solids precipitation unit 318 and 12 the solids are sent to the powdered metal recovery unit 322 while the inert gases are 13 sent to the inert gas recovery unit 320 which also supplies the vacuum;
and 4) 14 optionally, the delivery of inert gas from inert gas tank #3, 326 to the interior zone of the laser cladding nozzle channel is controlled by flow control valve 325. A weld or work 16 zone vision control system 330 observes the weld zone and provides control information 17 to the master control computer 327 based on the quality of the cladding being applied.
18 The weld zone vision control system 330 an be fixed in place, mounted on the robot 19 manipulator 305 or mounted on a separate robot manipulator, dependent upon the size and complexity of the surface 401 being laser clad.
22 [0028] Fig. 5 shows an alternate preferred embodiment where the vacuum port 214 is 23 curved and provided with a series of side ports 603 connecting to the coating port 212.
1 Negative pressure or vacuum acts to pull the inert gas jet that is carrying the powdered 2 metal along a curving surface built into the inner wall of the vacuum port. This will impart 3 a velocity towards the central axis of the laser nozzle of the gas jet and the powdered 4 metal that it is carrying. Such a configuration can place more of the powdered metal in the work zone. The side ports may be drilled into a wall connecting between the vacuum 6 port and the coating port. As shown in Fig. 5, more than one side port 603 may be 7 provided. Optionally the side ports 603 may be of varying sizes. As shown in Fig. 5, 8 the side port closest to the exit 99 is larger than the side port most remote from the exit.
9 The sizes may be sequentially larger as the side ports approach the exit, as shown.
The holes or side ports 603 through the outer wall of the inner compound cone 11 assembly can be drilled using a high powered laser.
1`) 13 [0029] With reference to Fig. 6, the inert gas flows out of and into the laser cladding 14 nozzle of the embodiment of Fig. 5 are shown with high levels of vacuum applied. Only the gas flows to one side of the laser cladding nozzle centerline 402 are shown for 16 clarity. The influence of the surface of the part 401 that is being laser clad is to 17 ultimately force all of the exiting inert gas flows, 404, 406, and 407 outward in a radial 18 direction away from the nozzle centerline 402 after they impinge onto the surface of the 19 part 401. The influence of a high vacuum induces a flow 403 of inert gases and solids into the laser cladding nozzle vacuum port 214. In the cases where there is an inert gas 21 flow into the interior zone of the nozzle delivery port then most of the inert gas 501 will 22 flow out of the interior zone into the vacuum port 214 to form part of the vacuum 23 channel flow 403. Most of the inert gas and powdered metal flow 406 exiting from the 1 coating port 212 travels in a several reverse flow paths 502 towards the nozzle 2 centerline 402 and enter the vacuum port to make up part of the flow 403.
Therefore 3 essentially none of the powdered metal being carried in the flow 406 exiting the inert 4 coating port 212 will reach the surface of the part 401 being clad. While some of the shaping gas flow 407 is still diverted away from the nozzle centerline 402 as shown by 6 gas flows 504 some of it as shown by gas flows 503 provide additional radial and 7 vertical pressure on the inert gas and powdered metal flow 406 thereby providing 8 additional impetus for the powdered metal to enter the vacuum port 214, and make up 9 part of the gas and material flow 403.
11 [0030] Based on the availability of additional powdered metal in the region of the laser 12 melt zone it would be beneficial to enlarge the size of the laser spot on the surface 13 being clad, using a variable focus depth of the laser beam and cladding a larger surface 14 area with every pass of the laser cladding nozzle. The laser spot size should be variable, since for detail work, a smaller spot will be required than for the cladding of 16 larger areas of the surface. Variation of the laser spot size at the surface being clad can 17 be effected by using a motor driven gear system similar to that used in camera zoom 18 lenses. It would also be beneficial to use a laser range finder, mounted to the laser 19 cladding nozzle, coaxially with the laser beam path to measure the distance to the surface being laser clad. This information can then be used in a control loop to adjust 21 the height of the laser focal spot relative to the surface being clad.
Fig. 7 shows an alternate preferred embodiment wherein the lens 26 is adjustably mounted. Fig. 8 is a schematic diagram where a controller for adjusting the laser work zone 903 on the surface of the part 401 being clad is shown. The control function is carried out by the master control computer 327 which gathers data from a coaxial laser range finder and sends movement commands to the focusing lens servo motor control 1002. The coaxial laser range finder 1001 can be any one of several commercial units available, based on laser triangulation, focal point determination, or modulation phase detection. The focusing lens servo motor control 1002 can also be a commercial unit that moves the laser focusing lens 26 and its mount 906 relative to the guide housing 905 based on advance or retract signals from the master control computer 327.
Fig. 4 the shows a schematic block diagram of the overall device controller and related components required for using the laser cladding device 10. Overall system control is provided by the master control computer 327 which provides coordination information to and receives data from the control elements in the system; namely, the robot controller, 328, the laser controller, 329, the shaping gas flow control valve, 303, the powdered metal mixing system, 308, the inert gas control valve for the powdered mixing unit, 313, the vacuum flow control valve, 316, the weld zone vision control system, 330, and the optional interior of the nozzle inert gas control valve, 325. There may of course be many other secondary control sensors that supply information on various aspects of the laser cladding system's operation to the master control computer, 327, their omission from Fig. 4 is done for the sake of simplicity only.
During operation, the laser cladding nozzle 20 is moved over the surface of the part being clad 401 through the use of a robot manipulator 305 under the control of the robot controller 328 as directed by the master control computer 327. Simultaneous with the movement of the laser cladding nozzle 20 over the surface of the part 401 being 1 clad, the laser, not shown, is focused by the laser cladding nozzle optics onto the 2 surface of part 401. At the same time the laser controller 329 controls the power output 3 of the laser as directed by the master control computer 327. Also at the same time, all 4 under the control of the master control computer 327: 1) the flow 302 of the inert shaping gas from supply tank #1 is controlled by flow control valve 303; 2) the flow 311 6 of inert gas from supply tank # 2 is metered into the powdered metal mixing system 308 7 by the gas flow control valve 313, while powdered metal is drawn from the powdered 8 metal supply tank 310 before the combined inert gas and powdered metal is delivered 9 to the laser cladding nozzle port 14; 3) the vacuum control valve 316 is used to control the level of vacuum present at the laser cladding nozzle port 14, the inert gases and 11 solids collected by the nozzle are passed through the solids precipitation unit 318 and 12 the solids are sent to the powdered metal recovery unit 322 while the inert gases are 13 sent to the inert gas recovery unit 320 which also supplies the vacuum;
and 4) 14 optionally, the delivery of inert gas from inert gas tank #3, 326 to the interior zone of the laser cladding nozzle channel is controlled by flow control valve 325. A weld or work 16 zone vision control system 330 observes the weld zone and provides control information 17 to the master control computer 327 based on the quality of the cladding being applied.
18 The weld zone vision control system 330 an be fixed in place, mounted on the robot 19 manipulator 305 or mounted on a separate robot manipulator, dependent upon the size and complexity of the surface 401 being laser clad.
22 [0028] Fig. 5 shows an alternate preferred embodiment where the vacuum port 214 is 23 curved and provided with a series of side ports 603 connecting to the coating port 212.
1 Negative pressure or vacuum acts to pull the inert gas jet that is carrying the powdered 2 metal along a curving surface built into the inner wall of the vacuum port. This will impart 3 a velocity towards the central axis of the laser nozzle of the gas jet and the powdered 4 metal that it is carrying. Such a configuration can place more of the powdered metal in the work zone. The side ports may be drilled into a wall connecting between the vacuum 6 port and the coating port. As shown in Fig. 5, more than one side port 603 may be 7 provided. Optionally the side ports 603 may be of varying sizes. As shown in Fig. 5, 8 the side port closest to the exit 99 is larger than the side port most remote from the exit.
9 The sizes may be sequentially larger as the side ports approach the exit, as shown.
The holes or side ports 603 through the outer wall of the inner compound cone 11 assembly can be drilled using a high powered laser.
1`) 13 [0029] With reference to Fig. 6, the inert gas flows out of and into the laser cladding 14 nozzle of the embodiment of Fig. 5 are shown with high levels of vacuum applied. Only the gas flows to one side of the laser cladding nozzle centerline 402 are shown for 16 clarity. The influence of the surface of the part 401 that is being laser clad is to 17 ultimately force all of the exiting inert gas flows, 404, 406, and 407 outward in a radial 18 direction away from the nozzle centerline 402 after they impinge onto the surface of the 19 part 401. The influence of a high vacuum induces a flow 403 of inert gases and solids into the laser cladding nozzle vacuum port 214. In the cases where there is an inert gas 21 flow into the interior zone of the nozzle delivery port then most of the inert gas 501 will 22 flow out of the interior zone into the vacuum port 214 to form part of the vacuum 23 channel flow 403. Most of the inert gas and powdered metal flow 406 exiting from the 1 coating port 212 travels in a several reverse flow paths 502 towards the nozzle 2 centerline 402 and enter the vacuum port to make up part of the flow 403.
Therefore 3 essentially none of the powdered metal being carried in the flow 406 exiting the inert 4 coating port 212 will reach the surface of the part 401 being clad. While some of the shaping gas flow 407 is still diverted away from the nozzle centerline 402 as shown by 6 gas flows 504 some of it as shown by gas flows 503 provide additional radial and 7 vertical pressure on the inert gas and powdered metal flow 406 thereby providing 8 additional impetus for the powdered metal to enter the vacuum port 214, and make up 9 part of the gas and material flow 403.
11 [0030] Based on the availability of additional powdered metal in the region of the laser 12 melt zone it would be beneficial to enlarge the size of the laser spot on the surface 13 being clad, using a variable focus depth of the laser beam and cladding a larger surface 14 area with every pass of the laser cladding nozzle. The laser spot size should be variable, since for detail work, a smaller spot will be required than for the cladding of 16 larger areas of the surface. Variation of the laser spot size at the surface being clad can 17 be effected by using a motor driven gear system similar to that used in camera zoom 18 lenses. It would also be beneficial to use a laser range finder, mounted to the laser 19 cladding nozzle, coaxially with the laser beam path to measure the distance to the surface being laser clad. This information can then be used in a control loop to adjust 21 the height of the laser focal spot relative to the surface being clad.
Fig. 7 shows an alternate preferred embodiment wherein the lens 26 is adjustably mounted. Fig. 8 is a schematic diagram where a controller for adjusting the laser work zone 903 on the surface of the part 401 being clad is shown. The control function is carried out by the master control computer 327 which gathers data from a coaxial laser range finder and sends movement commands to the focusing lens servo motor control 1002. The coaxial laser range finder 1001 can be any one of several commercial units available, based on laser triangulation, focal point determination, or modulation phase detection. The focusing lens servo motor control 1002 can also be a commercial unit that moves the laser focusing lens 26 and its mount 906 relative to the guide housing 905 based on advance or retract signals from the master control computer 327.
Claims (16)
1. A laser cladding device for applying a coating to a part comprising, in combination:
a laser that generates laser light configured to heat the coating and the part;
a main body defining a laser light channel configured to transmit the laser light to the part, a coating channel configured to transmit the coating to the part, and a vacuum channel; and a nozzle having an exit, comprising a delivery port at one end of the laser light channel, a coating port at one end of the coating channel, and a vacuum port at one end of the vacuum channel, wherein the vacuum port is positioned generally adjacent the delivery port, and in operation the vacuum port draws a vacuum;
a lens; and a controller configured to adjust the lens, wherein the laser heats the coating and the part in a laser work zone and the controller adjusts the lens such that a size of the laser work zone is variable.
a laser that generates laser light configured to heat the coating and the part;
a main body defining a laser light channel configured to transmit the laser light to the part, a coating channel configured to transmit the coating to the part, and a vacuum channel; and a nozzle having an exit, comprising a delivery port at one end of the laser light channel, a coating port at one end of the coating channel, and a vacuum port at one end of the vacuum channel, wherein the vacuum port is positioned generally adjacent the delivery port, and in operation the vacuum port draws a vacuum;
a lens; and a controller configured to adjust the lens, wherein the laser heats the coating and the part in a laser work zone and the controller adjusts the lens such that a size of the laser work zone is variable.
2. The laser cladding device of claim 1 wherein the vacuum port is positioned immediately adjacent the delivery port.
3. The laser cladding device of claim 1 wherein the vacuum port forms at least part of an annulus around the delivery port.
4. The laser cladding device of claim 3 wherein the coating port forms at least part of an annulus around the vacuum port.
5. The laser cladding device of claim 1 wherein the vacuum port is positioned around the delivery port, and the coating port is positioned around the vacuum port.
6. The laser cladding device of claim 1 wherein the nozzle further comprises a shaping gas port, a source of a shaping gas and a connection between the source of the shaping gas and the shaping gas port, and in operation the shaping gas is forced through the shaping gas port.
7. The laser cladding device of claim 1 wherein a vacuum level at the vacuum port is controlled by a flow control valve.
8. The laser cladding device of claim 1 wherein the vacuum port is provided with at least one side port interconnecting the vacuum port with the coating port.
9. The laser cladding device of claim 1, wherein the lens focuses laser light and is adjustably mounted in the laser light channel.
10. A laser cladding device for applying a coating to a part, comprising:
a laser;
a main body coupled to the laser and defining a laser light channel, a coating channel, and a vacuum channel; and a nozzle coupled to the main body that defines a delivery port coupled to the laser light channel, a coating port coupled to the coating channel, and a vacuum port coupled to the vacuum channel and positioned generally adjacent the delivery port;
a lens coupled to the nozzle; and a controller configured to adjust the lens, wherein, in order to apply the coating to the part:
(i) the coating travels through the coating channel to exit the nozzle through the coating port to generate a coating flow, (ii) the laser generates laser light that travels through the laser light channel to exit the nozzle through the delivery port to heat the coating flow and the part, (iii) a vacuum is generated by the vacuum channel and vacuum port in order to shape the coating flow, (iv) the laser heats the coating and the part in a laser work zone, and (v) the controller adjusts the lens to vary a size of the laser work zone.
a laser;
a main body coupled to the laser and defining a laser light channel, a coating channel, and a vacuum channel; and a nozzle coupled to the main body that defines a delivery port coupled to the laser light channel, a coating port coupled to the coating channel, and a vacuum port coupled to the vacuum channel and positioned generally adjacent the delivery port;
a lens coupled to the nozzle; and a controller configured to adjust the lens, wherein, in order to apply the coating to the part:
(i) the coating travels through the coating channel to exit the nozzle through the coating port to generate a coating flow, (ii) the laser generates laser light that travels through the laser light channel to exit the nozzle through the delivery port to heat the coating flow and the part, (iii) a vacuum is generated by the vacuum channel and vacuum port in order to shape the coating flow, (iv) the laser heats the coating and the part in a laser work zone, and (v) the controller adjusts the lens to vary a size of the laser work zone.
11. The laser cladding device of claim 10, wherein the vacuum port is positioned immediately adjacent the delivery port.
12. The laser cladding device of claim 10, wherein the vacuum port forms at least part of an annulus around the delivery port.
13. The laser cladding device of claim 10, wherein the coating port forms at least part of an annulus around the vacuum port.
14. The laser cladding device of claim 10, wherein the vacuum port is positioned around the delivery port, and the coating port is positioned around the vacuum port.
1 5 . The laser cladding device of claim 10, wherein the vacuum port is provided with at least one side port interconnecting the vacuum port with the coating port.
16. A laser cladding device for applying a coating to a part, comprising:
a laser;
a main body coupled to the laser and defining a laser light channel, a coating channel, and a vacuum channel; and a nozzle coupled to the main body that defines a delivery port coupled to the laser light channel, an annular shaped vacuum port coupled to the vacuum channel and surrounding the delivery port, and an annular shaped coating port coupled to the coating channel and surrounding the vacuum port, wherein, in order to apply the coating to the part:
(i) the coating travels through the coating channel to exit the nozzle through the coating port to generate a coating flow, (ii) the laser generates laser light that travels through the laser light channel to exit the nozzle through the delivery port to heat the coating flow and the part, and (iii) a vacuum is generated by the vacuum channel and vacuum port in order to shape the coating flow.
1 7. The laser cladding device of claim 16, wherein the vacuum port is positioned immediately adjacent the delivery port.
18 The laser cladding device of claim 16, further comprising:
a lens coupled to the nozzle; and a controller configured to adjust the lens, wherein the laser heats the coating and the part in a laser work zone and the controller adjusts the lens to vary a size of the laser work zone.
a laser;
a main body coupled to the laser and defining a laser light channel, a coating channel, and a vacuum channel; and a nozzle coupled to the main body that defines a delivery port coupled to the laser light channel, an annular shaped vacuum port coupled to the vacuum channel and surrounding the delivery port, and an annular shaped coating port coupled to the coating channel and surrounding the vacuum port, wherein, in order to apply the coating to the part:
(i) the coating travels through the coating channel to exit the nozzle through the coating port to generate a coating flow, (ii) the laser generates laser light that travels through the laser light channel to exit the nozzle through the delivery port to heat the coating flow and the part, and (iii) a vacuum is generated by the vacuum channel and vacuum port in order to shape the coating flow.
1 7. The laser cladding device of claim 16, wherein the vacuum port is positioned immediately adjacent the delivery port.
18 The laser cladding device of claim 16, further comprising:
a lens coupled to the nozzle; and a controller configured to adjust the lens, wherein the laser heats the coating and the part in a laser work zone and the controller adjusts the lens to vary a size of the laser work zone.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US99818807P | 2007-10-10 | 2007-10-10 | |
| US60/998,188 | 2007-10-10 | ||
| PCT/IB2008/003856 WO2009077870A2 (en) | 2007-10-10 | 2008-10-10 | Laser cladding device with an improved nozzle |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2702278A1 CA2702278A1 (en) | 2009-06-25 |
| CA2702278C true CA2702278C (en) | 2015-11-17 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2702278A Active CA2702278C (en) | 2007-10-10 | 2008-10-10 | Laser cladding device with an improved nozzle |
Country Status (4)
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|---|---|
| US (1) | US8117985B2 (en) |
| CA (1) | CA2702278C (en) |
| GB (1) | GB2465950B (en) |
| WO (1) | WO2009077870A2 (en) |
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- 2008-10-10 WO PCT/IB2008/003856 patent/WO2009077870A2/en active Application Filing
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| GB201006305D0 (en) | 2010-06-02 |
| US20090095214A1 (en) | 2009-04-16 |
| GB2465950A (en) | 2010-06-09 |
| US8117985B2 (en) | 2012-02-21 |
| WO2009077870A2 (en) | 2009-06-25 |
| GB2465950B (en) | 2012-10-03 |
| WO2009077870A3 (en) | 2011-04-28 |
| CA2702278A1 (en) | 2009-06-25 |
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